DMcCam wrote:Well, dang, 1/8" for the walls sounds like the ticket...how do you finish the wall to the frame? Do you run the 1/8" ply past the deck and cover the frame then laminate the aluminum to it? Or do you build the wall to be flush with the frame and just run the aluminum past to cover it? If you do that, how do you finish the bottom edge...?
Dave
Two ways I see, because 1/8" ply won't work well using your diagram (not much to catch the head of your screw through the single layer).
1) Bring your entire wall structure down to cover your frame. This is what I did on my build. The downside is I have exposed end grain ready and willing to soak up moisture if the epoxy ever fails.
2) Your second idea is perhaps my choice...place your wall on top of the deck, then extend aluminum down below that to cover the frame. Apply a generous bead of sealant such as SikaFlex to keep water from getting in between the aluminum and the frame by capillary action. If it were me, I'd probably just pop rivet the aluminum to the frame and skip any trim. I like this way because there would be no exposed end grain.
You mention "laminate the aluminum to the plywood." If you haven't yet, start thinking about how you're going to attach your aluminum. There are two basic methods: glue or float. A search on this forum will turn up several threads and a multitude of opinions. My choice was to float the skin using only screws and trim to hold it on. I've been happy with the results so far.
Brad
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Jack of all trades, master of none.
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Kampster build thread